Method of forming a tiled floor

ABSTRACT

A method of forming a tiled floor including the steps of (a) fastening a plurality of base modules ( 310 ) having a contoured top surface ( 330 ) to a ground surface and (b) laying tiles on the modules so that the surface of the tiles reflects the contoured surface ( 330 ) of the modules ( 310 ). In one form, the modules ( 310 ) are formed from an open grid which is filled by pouring concrete and any excess concrete scarped from the contoured top surface ( 330 ) of the grid before tiles are laid.

[0001] FIELD OF THE INVENTION

[0002] This invention relates to a method of forming a tiled floor.

BACKGROUND OF THE INVENTION

[0003] The construction of tiled concrete floors for wet areas, such asin bathrooms, is common. The usual method by which such floors areconstructed is for wet concrete to be poured and floated to form a floorpad. Special wet areas such as shower recesses are then shaped by handtrowelling to create a slope in the concrete pad leading toward a floorwaste outlet. Titles are then laid on the concrete to complete thefloor.

[0004] The problem with such forming is that they are highly dependenton the skill of the worker forming the concrete pad. Shower recesses aredesigned to allow water to flow towards the floor waste outlet that isusually located centrally in the shower recess. If an incorrectly shapedslope is present, water will tend to pool in an unwanted area. Theproblem is exacerbated when floor tiles are laid over the concrete.

[0005] The above problem also becomes more difficult to solve when theapplication is for an upstairs and/or timber floor system wherepreparation for waterproofing and mixing of sand and cement at the siteis required. Mixing concrete on upper floor levels involves carryingheavy bags of mixture which can contribute to a heavy and strenuousworkload often resulting in industrial accidents and back problems.There is also additional time involved in cleaning up the mixing toolsnecessary and the work areas.

OBJECT OF THE INVENTION

[0006] It is therefore an object of the invention to overcome oralleviate one or more of the above disadvantages or provide the consumerwith a useful or commercial choice.

SUMMARY OF THE INVENTION

[0007] In one form, although not necessary the only or broadest form,the invention resides in a method of forming a tiled floor, the methodincluding the steps of:

[0008] fastening a plurality of tiling base modules onto a groundsurface, said tiling module comprising a base having a top surface and abottom surface; and

[0009] laying tiles on said top surface of said tiling modules so thatthe contour of tiles reflects the contour of the top surface of thetiling module.

[0010] At least one of the tiling modules may be located over a floorwaste outlet. Preferably, the tiling module may have a top surface thatis inclined toward said floor waste outlet.

[0011] The tiling modules are formed from an open grid. In thisinstance, concrete may be poured over the module and any excess concretescraped from the top surface of the module. The concrete is then allowedto set so that the contour of the top surface is also reflected on theconcrete.

[0012] Alternately, the tiling modules may have a solid top surface. Thetiles may be laid directly onto the top surface without the need forconcreting.

[0013] The modules may be fastened to the floor using adhesives such asglue or mechanical fasteners such as, screws or nails.

[0014] In another form, the invention resides in a tiling module forforming a tiled floor, the tiling module comprising:

[0015] a base having a bottom surface and top surface;

[0016] said bottom surface able to be fastened to a ground surface andsaid top surface allowing tiles to be laid onto said top surface;

[0017] wherein said top surface is contoured to reflect the desiredcontour of laid tiles.

[0018] The base may be formed from an open grid. Alternately, the basemay be solid. Still alternately, the base may be formed from acombination of a grid and a solid top surface.

[0019] An aperture may be through the base for location of structuressuch as a floor waste outlet. The top surface may be inclined toward theaperture.

[0020] The module may have interconnecting elements adapted to allowinterconnection of adjoining modules.

[0021] Fastening means may be provided to allow the tiling modules to befastened to the floor using adhesives such as glue or mechanicalfasteners such as, screws or nails. For example, holes may be providedon the base for locating of mechanical fasteners.

[0022] Suitably the base has frangible areas to allow portions to bebroken off and removed. In the alternative, the base may be made frommaterial that can be cut.

[0023] Preferably the modules are fabricated from a corrosion resistantmaterial such as aluminium, stainless steel, galvanised iron or plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Embodiments of the invention, by way of example only, will bemade with reference to the accompany drawings in which:

[0025]FIG. 1 is a perspective view of a filed floor formed from tilingmodules;

[0026]FIG. 2 is a partial side view of the tiled floor according to FIG.1;

[0027]FIG. 3 is a plan view of tiling modules used in the floor of FIG.1;

[0028]FIG. 4 is a perspective view of a surround tiling module accordingto a first embodiment of the invention;

[0029]FIG. 5 is a perspective of a waste tiling module according to afirst embodiment of the invention;

[0030]FIG. 6 is a side view of the joined tiling modules of FIG. 4 andFIG. 5;

[0031]FIG. 7 is a perspective view of a waste tiling module according toa second embodiment of the invention;

[0032]FIG. 8 is a plan view of the tiling module according to FIG. 1;

[0033]FIG. 9 is a side view of the tiling module according to FIG. 1;

[0034]FIG. 10 is a perspective view of a connector;

[0035]FIG. 11 is a perspective view of a surround tiling moduleaccording to a third embodiment of the invention;

[0036]FIG. 12 is a cross sectional side view of the surround tilingmodule of FIG. 11;

[0037]FIG. 13 is a top view of the surround tiling module of FIG. 11;

[0038]FIG. 14 is a bottom view of the surround tiling module of FIG. 11;

[0039]FIG. 15 is a perspective of a different waste tiling moduleaccording to a third embodiment of the invention;

[0040]FIG. 16 is a cross sectional side view of the surround tilingmodule of FIG. 15;

[0041]FIG. 17 is a top view of the surround tiling module of FIG. 15;

[0042]FIG. 18 is a bottom view of the surround tiling module of FIG. 15;

[0043]FIG. 19 is a side view of the joined tiling modules of FIG. 11 andFIG. 15.

DETAILED DESCRIPTION OF THE DRAWINGS

[0044]FIGS. 1 and 2 shows a tiled floor 1 incorporating adjacent floortiling modules 10 shown in FIG. 3. The tiled floor 1 is formed byattaching the tiling modules to a ground surface 2 and then laying tiles3 onto the tiling modules 10. The tiled floor normally includes anaperture 50 for location of a floor waste outlet 4.

[0045] Each tiling module includes a base 20 having a top surface 30 anda bottom surface 40. The bottom surface 40 is flat to sit flush with theground surface 2. The top surface is configured so that the when thetiles are laid onto the top surface 30 of the tiling module 10, thetiles reflect the contour of the top surface 30. Various tiling modulesdesigns can be used depending various conditions such as load bearingcapabilities, weight and ground surface.

[0046]FIGS. 4 and 5 show a surround tiling module 110 and a waste tilingmodule 210 designed for fitting to timber floors. In this embodiment,the tiling modules 110 and 210 are of a solid configuration made out ofPVC, plastic, or a plastic composite materials that is lightweight andwaterproof. The tiling modules 110 and 210 are able to support normalfloor weights, are 30 mm high at its maximum and are designed as a 1 m×1m square section.

[0047] Each of the tiling modules 110 and 210 is formed from a base 120and 220 having a top surface 130 and 230 and a bottom surface 140 and240.

[0048] Tiling module 110 has a top surface 130 that is inclined at aconstant gradient throughout the length of the tiling module 110.

[0049] Tiling module 220 has an aperture 250 located adjacent the centreof the module for location around a floor waste outlet. Frangibleportions 251 are located adjacent the aperture 250. The frangibleportions are able to be broken to for a larger aperture 250 for largerfloor waste outlets. The top surface 230 of tiling module 210 isinclined toward the aperture 250.

[0050] The tiling modules 110 and 210 are designed to be locked togetherusing interlocking tongues 121 and 221 located on each of the modules.The tongues are interlocked as shown in FIG. 6.

[0051] A tiled floor is produced by first fastening tiling modules 120and 230 to the timber floor using adhesive. The tiling modules are alsointerlocked together using respective tongues 121 and 221. The tilingmodules 120 are 220 are cut and positioned to fit the shape of any areaor room shape. Once the tiling modules are fitted, the tiles are laidonto the top surface 130 and 230 of respective tiling modules 110 and210 to complete the tiled floor.

[0052] Any moisture/water, which inadvertently soaks through the tilescovering the tiling modules, is still be directed to flow into theregion of the waste outlet without coming into contact with the timberfloor itself. The advantage of the modular configuration is that timberfloors will not have to be waterproofed except at their edges. Theinvention in combination with waterproof glue prevents moisture fromgetting through to a timber floor system.

[0053] Further, the tiles are laid quickly and effectively with thecorrect fall as reflected by contour of the top surface 130 and 230 ofthe tiling modules 110 and 210.

[0054] FIGS. 7 to 9 show a waste tiling module 310 for forming aconcrete slab. The tiling module is formed from a base 320 having a topsurface 330 and a bottom surface 340. The base 320 is made frompolyvinylchloride. The base 320 is in the form of an open grid formedfrom vertical wall members 321 having holes 322 there between.

[0055] The top surface 330 of the tiling module 310 is inclined so thatthe top surface falls 330 toward the centre of the tiling module. Afloor waste can be located through a centre hole 323. It should beappreciated that other similar tiling modules may be formed to obtaindifferent falls as needed for other areas of a floor.

[0056] The tiling modules 310 come in 1 m×1 m square sections which linkand lock together to construct a floor area of any size. The modules arelinked and joined by plastic connector pieces 360 shown in FIG. 10. Theconnector has 361 adapted to accommodate ends of the vertical wallmembers of adjoining modules. The modules are fixed to reinforcementbars with connector clips (not shown) that click on the sides or comersof the module and click to the reinforcement bars. The module can alsobe tied the reinforcement bars with wire ties.

[0057] To construct a tiled floor, the tiling modules 320 are locatedover the areas of the floor including location over the floor wasteoutlet. Concrete is then poured over the tiling floor modules until theholes 322 are filled with concrete. A scraper is then used to scrape anyexcess concrete for the top surface 330 of the tiling modules 310. Theconcrete is then allowed to set. Tiles are then laid on the concrete andtop surface 330.

[0058] The advantage with this tiled floor is that the tiling modulesneed not be load bearing. The concrete is load bearing but reflects thecontour of the top surface 330. In turn, the laid tiles also reflect thecontour of the top surface.

[0059] FIGS. 11 to 14 show a further embodiment of a surround tilingmodule 410. The surround tiling module is formed from a base 420 havinga sold top surface 430 and a grid formed bottom surface 440. The tilingmodule is made from high density styrene and is load bearing.

[0060] A number of screw holes 460 are extend through the base 420 ofthe tiling module 410. The screw holes 460 allow for screws to belocated through the surround module and for the tiling module to befastening to a ground surface.

[0061] FIGS. 15 to 18 show a further embodiment of a waste tiling modulesimilar to the module shown in FIGS. 11 to 14. The waste tiling module510 is formed from a base 520 having a sold top surface 530 and a gridformed bottom surface 540. The tiling module is made from high densitystyrene and is load bearing.

[0062] A number of screw holes 560 are extend partially through the base520 of the tiling module 510. The screw holes 560 allow for screws to belocated through the surround module and for the tiling module to befastening to a ground surface.

[0063] In both the surround tiling module 410 and waste tiling module510, a lip 600 extends around the base adjacent the top surface. The lip600 is used for location of sealant between adjacent tiling modules asshown in FIG. 19 or the tiling module and wall. This prevents any waterpassing between adjacent modules.

[0064] Further, the waste tiling module 510 also has a four-sided flange570 that extends around the waste tiling module 510. The flange 570 isused to provide waterproofing. Two sides of the flange 570 extend aroundthe outside of the lip 600. This part of the flange 570 is used to abutagainst a corner of a wall and prevent water from contacting the wall.The other two sides of the flange 570 extend upwardly from the topsurface 530. The part of the flange prevents water from escaping throughthe waste tiling module 510 and potentially falling between adjoiningmodules 570. The flange 570 is able to be removed, for example using aplane, when not required. For example, if the waste tiling module 510 islocated at the centre of a room, then all the flanges 570 will beremoved.

[0065] The surround tiling module 40 and waste tilling module 510 can beused as described previously.

[0066] The method of forming a tiled floor as disclosed above has manyadvantages including reduced labour costs, more constant fall of tiledfloors and reduced time in completing a tiled floor.

[0067] It should be appreciated that various other changes andmodifications may be made to the embodiment described without departingfrom the spirit or scope of the invention.

1. A method of forming a tiled floor, the method including the steps of:fastening a plurality of tiling base modules onto a ground surface, eachsaid tiling module comprising a base having a top surface and a bottomsurface; and laying tiles on said top surface of said tiling modules sothat the contour of tiles reflects the contour of the top surface of thetiling modules.
 2. The method of claim 1 wherein at least one of thetiling modules is located over a floor waste outlet.
 3. The method ofclaim 2 wherein the tiling module has top surface that is inclinedtoward said floor waste outlet.
 4. The method of claim 1 wherein thetiling modules are formed from an open grid.
 5. The method of claim 4wherein concrete is over the tiling modules and any excess concretescraped from the top surface of the module.
 6. The method of claim 5wherein the contour of top surface of the tiling module is reflected bythe contour of the scaped concrete.
 7. The method of claim 1 wherein thetiling modules have a solid top surface.
 8. The method of claim 1wherein the tiling modules are fastened to the ground surface usingadhesives.
 10. The method of claim 1 wherein the tiling modules arefastened to the ground surface using mechanical fasteners.
 11. A tilingmodule for forming a tiled floor, the tiling module comprising: a basehaving a bottom surface and top surface; said bottom surface able to befastened to a ground surface and said top surface allowing tiles to belaid onto said top surface; wherein said top surface is contoured toreflect the desired contour of laid tiles.
 12. The tiling module ofclaim 11 wherein the base is formed from an open grid.
 13. The tilingmodule of claim 11 wherein the base is formed from a solid structure.14. The tiling module of claim 11 wherein the base is partially formedfrom a grid and a solid structure.
 15. The tiling module of claim 11wherein an aperture is located through the base.
 16. The tiling moduleof claim 15 wherein the top surface is inclined toward the aperture. 17.The tiling module of claim 11 wherein the interconnecting elements areprovide to allow interconnection of adjoining modules.
 18. The tilingmodule of claim 11 wherein fastening means are provided to allow thetiling module to be fastened to the ground surface.
 19. The tilingmodule of claim 11 comprising frangible portions that are broken off andremoved.
 20. The tiling module of claim 19 wherein the tiling module isfabricated from a corrosion resistant material.